Right to technical changes and errors reserved. 2012-07
D-02M-Abs2x (1.2)
Absolute Rotary Encoders
GEL 235/235x/203x
Single/Multiturn, SSI/Analog/Fieldbus
Interface
Mounting Instructions
2GEL 235/235x/203x
Device manufacturer and publisher:
Lenord, Bauer & Co. GmbH
Dohlenstraße 32
46145 Oberhausen ● Deutschland
Phone: +49 208 9963–0 ● Fax: +49 208 676292
Internet: www.lenord.de ● E-Mail: [email protected]
Doc. no. D-02M-Abs2x (1.2)
Lenord+Bauer Table of contents
GEL 235/235x/203x 3
Table of contents
1 About this manual ............................................................................................ 5
1.1 General information ................................................................................. 5
1.2 Validity ..................................................................................................... 5
1.3 Other applicable documents .................................................................... 5
1.4 Target group ............................................................................................ 6
1.5 Abbreviations and explanations of terms ................................................. 6
1.6 Symbols, signal words, notes .................................................................. 6
2 Safety instructions ........................................................................................... 7
2.1 Designated use ........................................................................................ 7
2.2 Notes for operators and manufacturers ................................................... 7
2.3 Modifications and conversions ................................................................. 7
2.4 Rotating parts .......................................................................................... 7
2.5 Notes about avoiding property damage and malfunctions ....................... 8
2.5.1 Handling of the encoders ............................................................ 8
2.5.2 Electrostatic discharge ................................................................ 8
2.5.3 Cable routing ............................................................................... 8
2.5.4 Mechanical overload of the bearings .......................................... 8
2.5.5 Saving battery power (GEL 2035 multiturn only) ........................ 9
2.6 EMC notes ............................................................................................... 9
3 Description ..................................................................................................... 11
3.1 Task ....................................................................................................... 11
3.2 Construction ........................................................................................... 11
3.3 Function ................................................................................................. 11
3.4 SSI data output ...................................................................................... 12
3.5 Adjustment possibilities ......................................................................... 12
4 Mounting ......................................................................................................... 13
4.1 Check fixture .......................................................................................... 13
4.2 Mount encoder ....................................................................................... 13
4.2.1 Synchro flange .......................................................................... 14
4.2.2 Clamping flange ........................................................................ 14
4.2.3 Semi hollow shaft ...................................................................... 16
4.2.4 Flex flange (GEL 2037) ............................................................. 17
4.3 Cable mounting with GEL 235 interface cover ...................................... 18
4.4 Lay cable ............................................................................................... 19
5 Commissioning .............................................................................................. 20
5.1 Connection ............................................................................................. 20
5.1.1 SSI ............................................................................................ 20
5.1.2 Analog ....................................................................................... 23
5.2 Function check ....................................................................................... 23
5.3 Measured value adaptation ................................................................... 24
5.3.1 PRESET (SSI, analog) .............................................................. 24
5.3.2 Teach-in (analog) ...................................................................... 24
5.3.3 Counting direction (SSI, analog) ............................................... 25
6 Disassembly and disposal ............................................................................ 26
6.1 Disassembly of the encoder .................................................................. 26
Table of contents Lenord + Bauer
4GEL 235/235x/203x
6.2 Disposal ................................................................................................. 26
7 Maintenance ................................................................................................... 27
8 Malfunctions ................................................................................................... 28
9 Technical data ................................................................................................ 29
9.1 Specifications ......................................................................................... 29
9.2 Dimensional drawings ............................................................................ 29
9.2.1 GEL 235 .................................................................................... 29
9.2.2 GEL 2351/2352 ......................................................................... 31
9.2.3 GEL 203x .................................................................................. 33
9.3 Mounting accessories ............................................................................ 34
9.4 Manufacturer's declaration ..................................................................... 36
Lenord+Bauer 1 About this manualGeneral information
GEL 235/235x/203x 5
1 About this manual
The absolute rotary encoders dealt with comprise the following devices:
Name Global features/pptions
Type
(1)
SSI Analog U Analog I Resolver Fieldbus
(2)
Ex protection
GEL 235 S, M1 X X C, E, P X
GEL 2351 S X X
GEL 2352 S, M1 X C
GEL 2035 S, M2 X X
GEL 2037 M1 X X
1.1 General information
These Mounting Instructions are part of the product and describe how to use it safely.
Please read the Mounting Instructions carefully before you begin installation.
Keep the Mounting Instructions in a safe place for the entire service life of the prod-
uct.
Make sure that the Mounting Instructions are available to personnel at all times.
Pass the Mounting Instructions on to each following owner or user of the product.
Insert all additions received from the manufacturer.
Failure to follow these Mounting Instructions may result in damage to the product,
which may result in its failure to operate as intended.
1.2 Validity
These Mounting Instructions apply to the standard design of the product. This includes
all types that are n o t marked with a Y behind the product number in the type code.
A product marked with Y is a customised design with a special assembly and/or modi-
fied technical specifications. Depending on the customised modification, additional or
other documents may be valid.
1.3 Other applicable documents
Depending on the device type, other documents may be applicable:
●Fieldbus reference CANopen
●Fildbus reference PROFIBUS-DP
●Fieldbus reference EtherCAT
(1)
S = single turn, M1 = mechanic multiturn (gear box), M2 = electronic multiturn (with buffer battery)
(2)
C = CANopen, E = EtherCAT, P = PROFIBUS-DP
1 About this manual Lenord + BauerTarget group
6GEL 235/235x/203x
●Operating instructions for GEL 235 Ex design
1.4 Target group
These Mounting Instructions are intended for operators, manufacturers, electrical en-
gineers, and licensed electricians under the supervision of an electrical engineer.
1.5 Abbreviations and explanations of terms
DC Direct current
ESD Electrostatic discharge, or Electrostatic sensitive device
EMC Electromagnetic compatibility
Encoder Short form of the term “absolute rotary encoder”
SW 17 (“Schlüsselweite”) A/F 17 mm (≈ 2/3 inch)
M4 Metric general purpose thread with 4 mm diameter
1.6 Symbols, signal words, notes
The following symbols, signal words, and notes are used in these operating instructions
so that you can recognize particular information faster:
Note about a possible danger
Failure to follow can cause death or severe injuries.
Note about a dangerous situation
Failure to follow can cause slight injuries.
Notes about avoiding property damage
Important information for the understanding and optimization of workflows
►Work step to be performed
→ page 6 Page reference to another part of these operating instructions
Lenord+Bauer 2 Safety instructionsDesignated use
GEL 235/235x/203x 7
2 Safety instructions
2.1 Designated use
The absolute rotary encoders are intended exclusively for measurement tasks in the
industrial and commercial realm. It is to be installed in a system and requires the con-
nection to special evaluation electronics, which, for example, are contained in a posi-
tioning controller or an electronic counter.
In the standard design, the GEL 235 absolute rotary encoder is not intended for use in
areas subject to explosion. For this, a special design is available. All other types must
not be used in areas subject to explosion.
Any other use is not a designated use.
2.2 Notes for operators and manufacturers
Personnel training
Make sure that the following requirements are met:
– Installation, operation, maintenance and removal tasks are only performed by
trained electricians under the supervision of an electrical engineer.
– Personnel has received training in electromagnetic compatibility and in handling
electrostatic-sensitive devices.
Provide personnel with all applicable accident prevention and safety regulations.
Ensure that personnel is familiar with all applicable accident prevention and safety
regulations.
2.3 Modifications and conversions
Unauthorized modifications or conversions may damage the product.
Do not make any modifications or conversions to the product, with the
exception of activities described in these operating instructions.
2.4 Rotating parts
Danger of injury due to rotating shafts
Hair and clothing can get caught in rotating shafts. Before performing all
work on the encoder, switch off the operating voltage to the drive shaft
and secure it against switching on again!
2 Safety instructions Lenord + BauerAvoiding property damage
8GEL 235/235x/203x
2.5 Notes about avoiding property damage and malfunctions
The encoders are designed to be extremely robust. Nevertheless, they can be damaged
due to impermissible mechanical loads. Mechanical damage can quickly cause the
failure of the measurement system.
2.5.1 Handling of the encoders
Do not hit or step on the housing or the shaft.
Do not open the encoder and do not take it apart.
Do not drill or grind the shaft or the housing.
Only mount the encoder as described in these Mounting Instructions.
Keep the load on the shaft as small as possible in order not to unnecessarily shorten
the life of the bearing.
Seal unused connector sockets by a cap or dummy/bus termination connector to
keep the specified protection class.
2.5.2 Electrostatic discharge
Electrostatic discharge can destroy the electronic components.
Only touch the plug pins and connection wires with suitable body grounding,
for example, using an ESD armband:
2.5.3 Cable routing
The connection cable can be damaged if it is bent too much.
2.5.4 Mechanical overload of the bearings
Due to a fixed mounting of the encoder on the fixture, forces are exerted on the
bearings. These cause permanent overloading of the bearings and thus shorten the
life span of the encoder.
►For the connection of the full shaft to the drive shaft, use a flexible coupling in
order to avoid an overloading of the bearings.
►Make sure that the maximum shaft loads are adhered to according to the spec-
ifications
Lenord+Bauer 2 Safety instructionsEMC notes
GEL 235/235x/203x 9
2.5.5 Saving battery power (GEL 2035 multiturn only)
The encoder can be put in a “sleep mode” to lengthen battery’s life (delivery condition).
This is applicable for the following situations:
●Longer lasting abandonment of the plant
●Storing the encoder as spare part
●Dismounting and subsequently storing an encoder
●Returning a defective encoder to the factory
For activation of the sleep mode the Preset function is used as described in section
5.3.1 (→ page 24), but with the encoder not being energized. The PRESET signal
voltage may vary between 3 VDC and 30 VDC.
When (re)energizing the encoder it supplies the adjusted PRESET value independent
of the position of the (resting) encoder shaft. Therefore, an electronic adjustment of the
encoder would be necessary to resume operation. For this reason, the sleep mode only
makes sense in those situations mentioned above.
2.6 EMC notes
To improve the electromagnetic environment, please heed the following installation
notes:
Use only plugs with a metal housing or a housing of metallized plastic as well as
screened cables.
Connect the screen, if provided in the screening concept, to the connector housing.
Apply the screens across a large area.
Keep all unscreened cables as short as possible.
Design the ground connections with a large cross-section (e.g. as induction-poor
ground strap or flat-band conductor) and keep them short.
If there are potential differences between machine and electronics ground connec-
tions, make sure that no equalizing currents can flow through the cable screen. To
do this, connect a potential equalization line with a large cross-section or use cables
with separated 2-way screening.
For cables with separated 2-way screening, connect the screens only on one side.
1
23
54
1
2
3
4
5
Machine
Absolute rotary encoder
Evaluation electronics
Control lines
Potential equalization line
(only for extreme disturb-
ance levels or long cables)
2 Safety instructions Lenord + BauerEMC notes
10 GEL 235/235x/203x
The sensor is part of a machine or system. Incorporate the potential equalization
for the sensor into the overall screening concept.
Lay signal and control lines spatially separated from the power cables. If this is not
possible, then use pair-stranded and screened cables and/or lay the encoder cable
in a steel conduit.
Make sure that external protective measures against surges are taken (EN
61000-4-5).
Lenord+Bauer 3 DescriptionTask
GEL 235/235x/203x 11
3 Description
3.1 Task
The absolute rotary encoder measures the angle of a machine axis via one or several
turns and delivers a corresponding digital output signal.
3.2 Construction
Exemplary illustration for GEL 235 with axial cable outlet (on the left) and radial con-
nector outlet (on the right):
1 Encoder housing
2 Mounting screw holes
3 Clamping flange, alternative: synchro
flange
4 Full shaft
5 PRESET button (opening on the back
side, optional)
6 Axial cable gland, alternative: radial ori-
entation or fieldbus/analog interface
cover
1 Plug connection, alternative: axial orien-
tation or fieldbus/analog interface cover
2 Encoder housing
3 Torque support
4 Clamping ring
5 Semi hollow shaft
6 PRESET button (opening on the back
side, optional)
3.3 Function
The sensing principle of the GEL 235 and GEL 235x is based on a touchless magnetic
scanning of a ferromagnetic steel disk (contour disk): Magneto-resistive sensors scan
three slightly-offset tracks and deliver corresponding sinusoidal signals. The phase po-
sition of the three sinusoidal signals is unique within a revolution.
Based on the vernier principle, the integrated electronics evaluate the phase position
and form the absolute position in the range of the existing resolution of the encoder
from this.
With the GEL 203x encoders, evaluation of the position of a diametral magnet mounted
on the shaft results in the corresponding absolute position.
Multiturn encoders use either a mechanic or an electronic gear (cf. table → page 5).
3 Description Lenord + BauerSSI data output
12 GEL 235/235x/203x
With the SSI variant, the position value is output serially in binary or grey code. Fur-
thermore, this encoder delivers 64 sin/cos differential signals per revolution for an ex-
ternal interpolation.
With the analog variant, the absolute position is output either as 0–10 V voltage or 4–
20 mA current values.
With the fieldbus variants (CANopen, PROFIBUS-DP), the data format and additional
functions are discussed in a separate document (Reference manual).
A separate electronic circuit is required for the supply of the encoder, the evaluation of
the measured value, and to build up the control loop.
3.4 SSI data output
The maximum clock frequency of 2 MHz applies only for very short transmission cables.
For longer cables, there arise the following limitations:
Cable length up to Max. clock
frequency Cable length up to Max. clock
frequency
50 m 400 kHz 200 m 200 kHz
100 m 300 kHz 400 m 100 kHz
The data and clock lines must be twisted and screened in pairs.
There must be a clock pulse space of at least 16 µs maintained between two position
queries.
Clock
Data
T
TP
MSB LSB
T Period duration of the clock signal (= 1/clock rate)
T
p
Clock pulse space
3.5 Adjustment possibilities
●Preset function: Adaptation of encoder measurement value can to the system-spe-
cific requirements (→ page 24)
●Sense of rotation: Electrically inversion (→ page 25)
●Teach-in function: Limitation of the encoder’s measurement range for achieving a
higher resolution (→ page 24)
Lenord+Bauer 4 MountingCheck fixture
GEL 235/235x/203x 13
4 Mounting
The following steps are required for the mounting of the encoder:
1. Check fixture
2. Mount encoder
3. Mount fieldbus cable with corresponding encoder type
4. Lay cable
4.1 Check fixture
For all required measurement details, see the dimensional drawings in section 9.2
(→ page 29ff).
Check whether all necessary holes have been made in the fixture.
If an encoder with full shaft is used, check whether an appropriate flexible coupling
is mounted on the drive shaft, e.g.:
4.2 Mount encoder
Tools and aids (not in scope of delivery):
●Mounting screws M4 with washers, possibly eccentric disks (see also section
Mounting accessories → page 34), the length of the screws depends on the wall
thickness of the encoder fixture (depth of the drilling holes in the encoders is 7 mm)
●Sealant for mounting screws if clearance holes are used (recommended: Loctite
542)
Danger of injury due to rotating shafts
Hair and clothing can get caught in the rotating shafts.
Before all work on the encoder, switch off the operating voltage to the drive shaft
and secure it against switching on again!
●Only touch the connector pins and wires with suitable body grounding, e.g. via
an ESD armband in order to prevent damage to the electronic components due
to electrostatic discharge.
●To connect the drive and full shaft encoder axis, use only a flexible coupling as
depicted in the pictures below.
4 Mounting Lenord + BauerMount encoder
14 GEL 235/235x/203x
Since the encoders can be used many different ways, the way it is attached is also
variable. Therefore, no step-by-step instructions for installation will be provided here,
but rather only a graphic overview of some usual mounting possibilities (mainly for
GEL 235). For the other encoders, similar procedures are applicable.
4.2.1 Synchro flange
●Mounting on a system-side housing wall using clamping pieces
4.2.2 Clamping flange
●Mounting on a system-side housing wall
Lenord+Bauer 4 MountingMount encoder
GEL 235/235x/203x 15
●Attachment on a mounting bracket (accessory part from LENORD+BAUER)
●Mounting using a clamping device
4 Mounting Lenord + BauerMount encoder
16 GEL 235/235x/203x
4.2.3 Semi hollow shaft
If not factory-adjusted:
Attach the torque supply to the encoder using four cross-head screws (1); tightness:
1 Nm.
Push the clamping ring loosely onto the semi hollow shaft (2).
Push the encoder onto the drive shaft and screw the torque support onto the fixture:
Jam the clamping ring with the M3 Allen screw; tightness: 1 Nm.
12435 6
1
2
3
4
5
6
Drive shaft
Fixture
Semi hollow shaft
Torque support
Clamping ring
Encoder
Lenord+Bauer 4 MountingMount encoder
GEL 235/235x/203x 17
4.2.4 Flex flange (GEL 2037)
Push the Flex flange onto the clamping flange of the encoder (1).
Turn the encoder slightly until its three M4 threaded holes fit the corresponding bore
holes in the Flex flange (2).
Join both parts by means of three cylinder head screws (3); tightness: 2.5 Nm.
Mount the unit to the designated fixture (customer-specific).
123 4 5
1
2
3
4
5
Encoder shaft
Fixing screws
Customer-specific fixture
Flex flange
Encoder
4 Mounting Lenord + BauerCable mounting with GEL 235 interface cover
18 GEL 235/235x/203x
4.3 Cable mounting with GEL 235 interface cover
Disconnect the interface cover and encoder: Remove 2 screws on the back side of
the interface cover.
Prepare the cable gland, bus cable, and supply cable (only PROFIBUS) as follows
and mount:
55 mm
8 mm
12 mm
6 Nm
After performing the connection work, connect the interface cover and encoder:
Tighten 2 screws on the back side of the interface cover.
Check the housing seal to ensure that it is seated correctly.
Seal bushings that are not needed with a blind cover.
5 Commissioning Lenord + BauerConnection
20 GEL 235/235x/203x
5 Commissioning
Check whether all cables are laid and the encoder is mounted firmly.
5.1 Connection
Connection of the fieldbus variants: → separate Reference document.
Check whether the connector plug is wired correctly, according to the connection
schemes further below.
Connect inputs that are not used/assigned to GND.
Connect the encoder.
Supply the encoder with voltage.
5.1.1 SSI
8-pole connector M12 (GEL 2352)
Pin Signal Explanation
1 GND Ground
2 PRESET Set actual value to centre of measurement range
3 DATA- Output: Differential data signal according to RS 485
4DATA+
5CLOCK-
Input: Differential clock signal according to RS 485
6CLOCK+
7V
S
Supply voltage
8 CW/CCW Direction of rotation (flange side view):
ascending clockwise (CW) = GND (default), ascending counter-clock-
wise (CCW) = V
S
1
8
2
73
64 5
Connector socket (pins, connection side view)
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